Note: Descriptions are shown in the official language in which they were submitted.
CA 02105660 2001-10-23
Supporting element for use in casting concrete floors
The present invention relates to a supporting element with elongate form for
use
in casting concrete floors on a foundation, said support element comprising a
base member and a top member with a sliding plane surface to allow a concrete-
levelling device carried by the supporting element to be moved along the
sliding
plane surface.
Known supporting elements of the type described in the introduction consist of
beam-like bodies of reinforced concrete, the sliding plane surface thereof
usually
having a width of 2.5-7 cm. The concrete beams are cased-in to form a part of
the finished concrete floor so that the sliding plane surface will be on a
level
with the surface of the finished concrete floor. A drawback with such cast-in
concrete beams is that cracks appear first along one side of the top of the
beam
and then along the other side. After some years the top of the beam and its
sliding plane surface are damaged or destroyed entirely or partly and
expensive
repair work is necessary. Furthermore, the damages on the top of the beam is
accelerated by the trussing irons inside. The grade of concrete used for
manufacturing the beams is extremely important. When using such concrete
beams, the application of a covering layer is limited as well as securing the
trussing irons. Furthermore, the concrete beams can only be used for casting
concrete floors on the ground. On other foundations such as ceilings there is
insufficient cohesion between fresh and solidified concrete since the concrete
beam separates them. In foundations formed of cassettes, i.e. prefabricated
joist frames of concrete, steel or light concrete, problems may arise with the
adhesion between concrete beam and cassette. Another problem is that
levelling of the concrete beams is relatively time-consuming and complicated
since the beams are heavy and are positioned in fresh concrete which must
solidify before casting can be performed. Furthermore, handling of the
concrete
beams during manufacture, storage at the factory, transportation, storage at
the
retailer and on site, is relatively expensive due to their fragility and high
weight.
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CA 02105660 2001-10-23
The object of the present invention is to provide a supporting element which
greatly reduces the above-mentioned problems; which has low weight and is
thus easily handled; which can be quickly and easily levelled ensuring that
the
sliding plane surface is at the desired level; which reduces the risk of
cracks in
the finished concrete floor; which allows great freedom in mounting trussing
irons; and which is not limited to casting on the groung but can also be used
when casting cassettes and ceilings.
The invention is characterized substantially in that the supporting element
comprises two longitudinal, form stable side walls defining between them a
longitudinal space, and that at lest one of the side walls is provided with a
plurality of through-holes disposed to permit fresh concrete to flow through
into
said space during said casting, so that the space s filled with concrete.
The invention will be described further in the following, with reference to
the
accompanying drawings.
1 5 Figure 1 is a perspective view of the supporting element according to a
first
embodiment of the invention.
Figure 2 is an end view of the supporting element according to Figure 1 .
Figure 3 is a perspective view of a supporting element according to a second
embodiment of the invention.
Figure 4 is an end view of the supporting element according to Figure 3.
Figures 5-7 are end views of supporting elements according to three further
embodiments of the invention.
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CA 02105660 2001-10-23
Figure 8 is a view from above or part of a foot portion with screw, of the
supporting element according to Figures 3 and 4.
Figure 9 is a section along the line IX-IX in Figure 8.
The supporting element shown in Figures 1 and 2, generally denoted screed, has
an elongate, rail-like form and comprises a base member 1 intended to face
downwardly to the foundation on which a concrete floor is to be cast, and a
top
member 2 having an upwardly facing sliding plane surface 3 on which a
concrete-levelling device is intended to rest in order to slide on along said
surface 3 when being moved along the supporting element. According to the
present invention the supporting element comprises two longitudinal, form
stable, i.e. rigid side walls 4,5 which, seen in a cross section of the
supporting
element, extend between the top member 2 and the base member 1 . Between
them the side walls 4,5 define a free space 6, which extends continuously
between the ends of the supporting element. According to the present invention
each side wall 4,5 is provided with a plurality of through-holes 7,8
distributed
evenly across the entire side wall in a plurality of horizontal rows. Each
hole,
7,8 is sufficiently large to permit fresh concrete to flow freely through the
side
walls into the space 6 and collect therein, and the number of openings 7,8 is
sufficient and their distribution so event that their entire space 6 will be
filled
with concrete when the supporting element lies embedded in the concrete,
before the concrete has had time to solidify. The expression "form stable side
walls" means that the walls are sufficiently strong to bear the weight of said
concrete-levelling device without becoming deformed.
In the embodiment shown in Figures 1 and 2 the side walls 4,5 are inclined in
relation to each other so that they form an acute angle with each other.
Within
the top member 2 the side walls 4,5 are firmly connected together to form a
form stable unit. The base member 1 comprises a foot portion 9,10 at each side
wall 4,5. The foot portion 9,10 is rigidly connected to the side wall 4,5 and
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CA 02105660 2001-10-23
protruding away from the space 6. The foot portions 9,10 are also provided
with a plurality of through-holes 1 1 ,12 for the passage of fresh concrete to
the
lower side of to foot portions 9,10, particularly when the foot portions are
adjusted so as to keep at a distance above the foundation. It will be
understood
that the holes 7,8,9,10 result in considerable saving in material and reduced
weight. However, the greatest reduction in weight of the supporting elements
is
achieved thanks to the space 6.
The supporting element, or more precisely supporting and levelling element, is
preferably produced from a flat sheet-metal blank which is bent so that the
foot
portions 9,10 and side walls 4,5 are connected at the folding lines between
them. The junction or ridge 13 between the side walls 4,5 can be designed in
various ways, itself forming either the whole top member 2, or a part of this.
In
the embodiments shown the ridge 13 forms a part of the top member 2 which
thus includes a second part in the form of a form stable body 14 forming a
rail,
said body being disposed above and anchored firmly to the ridge 13.
In the embodiment shown in Figures 1 and 2 this is achieved by the ridge 13
being formed with an upwardly directed flange 15, while the rail 14 is
provided
with a corresponding groove 16 to receive the flange 15, thus securing the
rail
14 to the ridge 13. The rail 14 may be detachably joined to the ridge 14,
which
is advantageous in the case when the rail 14 is to be removed after casting.
In the embodiment shown in Figures 3 and 4 the ridge 13 of the top member 2
is formed with a longitudinal groove 17, in which case the body 14 of the top
member 2 is provided with a lower portion 18 having a thickness corresponding
to the width of the groove 17, permitting the rail 14 to be mounted into the
groove 17 and retained therein to give a firm engagement. This embodiment can
be used advantageously for casting in two steps, the supporting element shown
in Figures 3 and 4 being positioned for casting a first, thicker layer of
concrete
and an elevating rail (not shown) then being applied on top of the supporting
element. Such an elevating rail may be designed as the rail 14 in Figures 1
and
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CA 02105660 2001-10-23
2 and forms a second sliding plane surface located at a predetermined
distance,
e.g. 10 mm, above the first sliding plane surface 3. A op layer of hard
concrete
is thereafter applied and levelled, having a thickness thus corresponding to
said
distance, i.e. 10 mm in the example given.
The supporting element according to the invention preferably also includes
means for adjusting the sliding plane surface 3 to bring it to the desired
level for
the concrete -levelling device. Such level-adjustment means preferably consist
of screws 19, each with a shaft corresponding to the size of the holes 1 1,12
in
the foot portions 9,10 so that the screws 19 can be brought into thread
engagement with the edges of the holes as shown in
Figures 3 and 4. By turning the screws 19 in one direction or the other, the
vertical position of the supporting element can be quickly and easily
adjusted.
To facilitate screwing the screw 19 may be provided with an engagement means
for a turning member, e.g. a hole 20 in the upper end of the screw with
rectangular cross section. The holes, or the selected holes 1 1,12, e.g. every
fourth hole, designed for screws 19 may advantageously be shaped so that the
edge of the hole corresponds to the thread pitch of the screw 19. This is
easily
achieved by a slit 25 being made in the edge portion 26 of the hole, as
illustrated in Figures 8 and 9, the length of the slit 25 being slightly
greater than
the depth of the screw thread. The edge portion 26 of the hole on each side of
the split 25 is bent apart to form a groove 27 to close to the slit 25 which
corresponds substantially to the screw thread, the bending incline decreasing
to
zero at the diametrically opposite side of the hole edge as illustrated in
Figure 9.
In the case of hard foundations such as ceilings it is sufficient for the
lower ends
of the screws, possibly provided with a small support head, to rest against
the
foundation. When the foundation is the ground it is advisable for the screw 19
to be placed on a separate supporting plate 21 as shown in Figures 3 and 4.
Instead of using screws and support plates, concrete spots may be placed out
on the foundation in conventional manner if it consists of ground or
cassettes, in
which concrete spots the supporting elements are adjusted to the correct
level.
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When the foundation consists of ceilings or cassettes special plastic spaces
may
be used to being the supporting element and trussing irons to the desired
level.
Special locking means may be used to prevent the side walls 4,5 from being
forced apart, such as clamps 22 which are secured to and extend between the
foot portions 9,10 as shown in Figures 1 and 2.
In the embodiments shown the holes 7,8 are arranged in three separate rows in
each side wall 4,5. This offers great freedom when mounting the trussing
irons.
In the embodiment shown in Figures 1 and 2 a barrier member for the concrete
is arranged in the space 6, e.g. a curtain 23 of flexible material as shown in
Figure 2, which is secured at its upper edge to the inside of the ridge 13,
the
other edge being free and extending to the level of the foot portions 9,10.
The
curtain 23 thus hands freely in the space 6. When a floor is being cast in
compartments the curtain 23 prevents concrete entering through one of the
walls 4 or 5 from flowing out through the other side wall 5 or 4, respectively
since the concrete flowing into the space 6 presses the curtain 23 into
contact
with the inside of the other side wall 5 or 4, respectively, thus closing the
holes
8 or 7, respectively. Any unfilled spacs in the space 6 will be filled with
concrete when casting is performed on the other side of the supporting element
in the adjacent compartment.
In the embodiment shown in Figure 5 the ridge 13 has a flat, horizontal
surface
and the form stable body 14 forming the rail has a correspondingly flat
surface
enabling it to be anchored by means of a suitable adhesive, for instance.
In the embodiment shown in Figure 6 one side wall 4 is inclined and provided
with holes 7 as described above, the other side wall 5 being vertical and more
over has no holes. The supporting element forms a barrier and prevents
concrete from running from one side to the other. It can be used against a
wall,
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for instance, in which case the imperforated side wall 5 should face the wall.
The side wall 5 in this embodiment may be covered by a material, e.g. a soft
or
insulating material, in order to suppress sound in the frame when the
supporting
element is placed against a wall. The vertical side wall 5 need not have a
foot
portion.
In the embodiment according to Figure 7 one side wall 4 is inclined and the
other
is vertical. Both side walls 4,5 are provided with holes 7,8 as described
above.
The vertical side wall 5 has a recess at its mid-section so that a
longitudinal
groove 24 is formed. This groove 24 is filled with concrete so that the
finished
concrete floor has a corresponding protuberance and the groove 24 and this
protuberance form in situ a tongue and groove joint, thereby preventing
vertical
displacement of the concrete floor at the joint. According to an alternative
embodiment (not shown) the vertical side wall 5 is provided with a
corresponding protuberance instead of the groove and an equivalent tongue and
groove joint is thus obtained at casting.
The supporting element comprising foot portions 9,10, side walls 4,5 and ridge
13 may be made of plastic, metal such as steel or expanded metal, wood, wire-
netting or sufficient thickness (rigid), or concrete. The body 14 forming a
rail
may consist of plastic, wood or metal, for instance. When the rail 14 is a
detachable separate body, it may be removed, if desired, when the concrete
floor has solidified, in which case the groove thus obtained in the floor is
filled
with suitable joining compound used for wear floors.
Since the side walls 4,5 incline outwardly from the top member of the concrete
can more easily flow in through the holes. The inclined side walls 4, 5
suitably
form an acute angle of 25°-90°, preferably 30°-
60°, with each other.
